Bat forming apparatus



` Jan. 15, 1957 Filed June 26, 1953 3 Sheets-Sheet 1 trg-:7 V' vvf" 'e L iQ E* /I l :j u N;

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INVENTO {TTORNEYS Jan. 15, 1957 Filed June 26, 1953 F. R. MARINDIN 2,777,170

BAT FORMING APPARATUS 3 Sheets-Sheet 2 v BY i Jan. 15, 1957 Filed June 2G, 1955 5 Sheets-Sheet 3 United States Patent BAT FORMING APPARATUS Frederick R. Marindin, Bethel, Conn., assgnor to Doran Brothers, Inc., Danbury, Conn., a corporation of Connecticut Application June 26, 1953, Serial No. 364,269

13 Claims. (Cl. 19-148) This invention relates to an apparatus for depositing pending appli-cation Serial No. 284,270, filed April 25,

1952, now abandoned.

The -description to follow will be principally confined to the use of such a method and apparatus in the batting industry. However, both may be also usedy in related arts such as the manufacture of various articles from fiber glass, e. g., tank-like containers, etc.

Every hat manufacturing plant has one or more forming machines, into which fur fibers are fed lto be showered on the outer surface of a form, usually a coni-cal screen. This mat of fur isr then moistened causing the fibers to adhere lto each other loosely so that this lbody usually referred to as a hat m-ay be peeled off. The bat at this stage is very fragile and must be handled `with great care and skill to avoid irreparable dam-age. Because the fur is deposited on the outside of the form in existing forming machines, the forms must be turned over so that the bat may lbe carefully and slowly peeled ot and then prepared for the felting and shrinking operations to follow. This stripping operation must belperformed with utmost care and even so, loss through damage is considerable at this point in hat manufacture.

Large quantities of :air `are used in the operation of these machines and present forming machines are rather crude in the regulation of .such air, making control of the amount of fiber deposition on different parts of the form diicult. Due to various obstructions and irregularities in the induced path of the air, eddies develop sometimes making for irregular fiber distribution Where not desired. These diiculties plus those attendant upon maintenance of proper temperature and humidity conditions make the present forming machines difficult to oper- `ate and this naturally requires skillful operating supervision Iat all times.

llt is accordingly among the objects of this invention to provide .an apparatus for and method of forming hat bats which obviate the aforementioned difficulties as well as others in a -thoroughly practical and eicient manner. It is a further object -to provide in such apparatus the qualities of simplicity of structure and operation, durability over extended periods of use, uniformly reli- -able performance, `and eicient operation by'relatively unskilled personnel. A still further object is to provide a method of form-ing hat bats which lreduces -to a minimum damage from handling, while lat the same time effecting and maintaining high production of uniformly high quality bats. Other objects willbe in part apparent and in part pointed out hereinafter.

ln the drawing, Iwherein lI have shown one form of my invention,

[Figure 1 4is a schematic fragmentary side elevational view, partially in section of a machine having fan embodiment of the invention incorporated therein;v

2,777,170 Patented Jan. 15, 1957 'ice Figure 2 is a sectional elevation taken along the Iline 2 2 of Figure 1;

'Figure 3 is a schematic vertical sec-tion illustrating one operative position of the air diffuser incorporated in the machine;

Figure 4 is a view similar to Figure 3, but showing Ithe diffuser in another opera-tive position;

Figure 5 is a schema-tic, fragmentary view partially in section of another embodiment of the invention;

Figure 6 is a schematic vertical section similar to that of Figures 3 and 4 but showing a further embodiment of the invention, and

Figure 7 is a sectional view taken along the line 7--7 of Figure 6.

Similar reference characters refer to similar parts throughout the views ofthe drawing.

In one embodiment of my invention, a measured quantity of properly prepared fibers (fur fibers in the hatting industry) is fed into a stream of air Which is Warm and has a relatively high moisture content. This fiber-laden stream of air is directed to the inside of .a rotating perforated form, e. g. Ia cone, and at the same time supple'- mentary diffusing non-fiber bearing air is introduced in such a manner as to control the thickness of fiber deposit on the inner .surface of the cone. In other words, the diffusing air is so introduced that the fiber deposit at the base -of the cone may be thicker than that at the tip of the cone, or vice versa. As the fibers are deposited on the form, all `of lthe air ows lthrough the perfor-ations of the cone and is exhausted by a suction fan into a duct connected to the inlet side of the cone so that it may be partially or completely recirculat-ed. If desired, a portion of the recirculated air may be exhausted into the workroom from which it may be drawn -for use as diffusing air, thus avoiding loss of heat or moisture con tent.

After sufficient fibers have been deposited on the inner surface of the form, they are thoroughly moistened in the case of a hat bat to start shrinking and interlocking of the fibers. The exterior surface of the form is then subjected to air pressure thus to strip the bat from the inner surface of the form to lbe removed in Vany suitable manner.

This method of ber deposition may be practiced on a machine With `a partial Vacuum maintained in the forming chamber by an exhaust fan. The perforated form, illustra-tively a perforated cone, is rotatably mounted therein with its open end facing the inlet for fiber-laden and diffus-ing air. Thus in hat manufacture, the fur fibers are deposited on the inner surface of the form which is mounted on `a turntable for rotation. Other types of fibers may be deposited in a similar manner on forms of .any desired shape and suitably processed to hold them together to form a loose body which may be removed for molding or other final finishing step.

More or less conventional fur picking and feeding apparatus may be used to feed fibers into an air chamber adjacent the form where a tube-like diluser is located to deliver non-fur bearing air to the form. This diffuser is adjustable and its position may be varied relative to the form whereby the thickness of fiber deposit on the inner surface of the cone may be controlled from the base to the tip of the form. Air which has passed through the form may be returned and mixed with fiberfree air from the diffuser and fiber-laden air from the feeder by suitable dampers. Such recirculated air may be controlled to accurately effect the exact desired lay of bers on the inner surface of the form.

The embodiment of the invention illustrated in Figure 1 of the drawings includes a main frame 10, which supports a forming chamber, generally indicated at 11,

within which a perforated form, generally indicated at 12, is rotatably mounted. YThe outlet end of forming chamber 11 is connected to a suction fan 13, in turn connected toA a duct 14.A A riser 15 connects duct 14 to an air chamber, generally indicated at 16, which not only receives recirculated air by Way of riser 15, but also fur or fiber particles from the picking and feeding'mechanism, generally indicated at 17, i. e., it forms a mixing area. Thus, when the machine is in operation, a mixture of fur and air ows into air chamber 16, from which it is sucked into form 12 where the fibers are deposited. After sufficient fiber deposit has been effected, it is moistened, if the fibers are fur, and thereafter the thusly formed bat isremoved, all as will be described in greater detail hereinafter.

Forming chamber 11 includes a casing 18 and a tapering portion 19 terminating in the exhaust end 2t) connected to housing 21 of the fan. Fan 13 is driven by a motor 22 and a gate valve 23 controls the inlet from chamber 11. While forming chamber 11 and form 12 are shown horizontally disposed, these parts could be mounted vertically by a realignment of the suction fan 13, duct 14, riser 15 and air chamber 16, as well as theA picking and feeding mechanism.

Fan 13 exhausts into the upper end 14a of duct 14, in turn connected with horizontal portion 14h, which underlies the machine, and exhausts into the worliroom by way of its exhaust end 14e underlying the picking and feeding mechanism 17; this exhaust end may be provided with a damper 24. Also mounted in duct 14 are a pair of dampers 25 and 26, which may be adjusted for certain purposes, as will `be described hereinafter. Riser 15 is located generally at the front of the machine and at its upper portion 15a communicates with a housing 27 within which is disposed conventional ber feeding mechanism. Thus, adjacent the lower end of housing 27, there is an inclined apron 33 for feeding tfibers to a wire mesh feed drum 32 which, in turn, transmits the fibers to the feed rolls 32a and 32h, adjacent the picker 31. In the upper portion of the housing 2 7, there are drums 28 and 29, feed rolls 29a and 29b and a picker 30. ln fact, any standard mechanism for feeding fibers to the charn ber 16 may be used.

The upper `end of riser 15 communicates with an inlet opening 34 of a housing 35 which in general'comprises air chamber 16. Housing 35 is pivotally mounted, as at 36, so that it may be swung between the full and broken line positions shown. Adjustably mounted within housing 35lis an air diffuser, generally indicated at 37, this diffuser including a cylindrical support 38 which is secured to air chamber housing 35 in any suitable manner. i Slidably mounted within cylindrical support 38 is a tube-like member 39 whose inlet end 40 communicates with the workroorn, and in which has a flared outlet end 41 delivering air withdrawn from the Workroorn to the inside of form 12. A rack 42 on the lower side of tubel 394 meshes with a pinion 43 fastened to a cross-shaft 44 (Figure 2), whose end 45 carries a crank 46. Thus manipulation of crank 46 slides tube 39 (Figure l) relative to its support 38 and locates the discharge end 41 relative to form 12, this for a purpose to be later described. Tube 39 also carries an inner -tube 47 supported therein by` radially disposed fins 50 attached to tubes 39 and 47; the end 48'of tube 47 is preferably flared. By thus flaring these tube ends, a better diffusion of air is possible.

Form 12, which illustrativelyis shown in the shape of a cone, such as would be used in the forming of a hat bat, is suitably perforated and has its base or brim portion secured to a turntable 51.` This turntable includes an annular fiange-likeportion 52, which is supported against the front side of a supporting plate 53 by suitable bearings 54. The turntable also includes a cylindrical flange 55 which extends through an annular opening 5.6` in plates 53, this cylindrical` flange riding on a set of rollers 57 0carried` by plate` 53 (see also `Figure 2).

Turntable 51 is provided with a belt groove 59 to receive a belt 60, which is also trained about a driven pulley 61 to rotate the turntable 51 and form 12 in forming chamber 11.

As shown in Figure 2, a supporting arm 62 is secured to and extends from plate 53 and pivotally supports at 63 a hot water pipe 64 connected by a hose 65 to a source of water. A nozzle or spray attachment 66 on the other end of pipe 64 may be swung into position to wet the fibers in the form when air inlet housing 35 is swung to the broken line position shown in Figure l. With the form still rotating, a spray of hot water may be directed into the form against the lay or deposit of fibers, and maintained until the fibers have been sufficiently shrunk and interlocked to provide suflicient adherence so the bat may be removed without damaging it. Air suction may then be cut off by closing sliding valve 23 or, if desired, stopping motor 22. Water flowing through the form into forming chamber housing 18 drains therefrom by way of a pipe 67.

A blower 68 is mounted on casing 18 with its discharge 69 disposed within the forming chamber. After wetting as above described, blower 13 may be stopped, nozzle 66 may be swung out of the way and blower 68 turned on whereupon the air so introduced raises the pressure in the forming chamber on the outside of the form. The discharge end 69 of this blower is preferably located near the base of form 12, and as the form rotates, the blast of air emanating therefrom plus the increased pressure pushes the bat away from the inner surface of form 12, i. e., near the point of its larger diameter. Accordingly, the bat is progressively stripped or collapsed from the larger to the. smaller diameter thereof, both by reason of the direct action of. the air discharge from blower 68, and also from the increased air pressure in` former chamber 18. After the bat has been completely stripped from the form, it may be manually removed, or, provision may be made for its automatic removal. A conveyor belt 70is driven in any suitable manner as by belt 71 and motor 72 located adjacent but below the base of form 12. Continued rotation of form 12 will cause the newly formed bat to fall on the belt for removal from the machine. By depositing the fibers on the inside of the cone, as is done in this machine, the possibility of damaging the bat during stripping is greatly reduced, andv considerable time is saved. After the bat has been removed air inletv housing 35 may be swung back to its full line position, blower 68 turned off, valve 23 opened, fan motor 22 turned on and the several dampers readjusted asis necessary. The machine is thus set for formation ofthe next bat.

ln the manufacture of hats, it is desirable to control the thickness of different sections of the bat with considerable accuracy. Sometimes, greater thickness is desired at the brim portion and sometimes just the reverse, and it is well recognized that with conventional formers, such control is difficult. To a large extent these difficulties are rectified by the air diffuser 37.

In the arrangement shown in Figure 3, the diffuser is positioned for a heavier liber deposit around the brim portion 12b of form 12 while in Figure 4 the diffuser is located to provide a heavier lay at the tip portion 12a of the form. It will, of course, be obvious that either before or during the deposit ofthe bers, the position of the diffuser can be varied by manipulation of crank 46 (Figure 2) or by automatic controls (not shown) as may be necessary to obtain the character of fiber deposition desired.

With the diffuser in the Figure 3 position, one fiberladen air stream ows from riser 15 throughchamber 35V and past diffuser 37 through the annular space 35a while the other non-fiberladen stream comes through` the diffuser and out discharge ends 41 and 48. Accordingly,

the discharge. ends` of the diffuser direct" the bulk of the` non-tiber-laden` air toward that section of form 12 in the vicinity of the brimportion 12b thereof. This directsy the ber-laden air from the annular space 35a towards the brim portion 12b of the form where it is retained by the suction of fan 13 on the forming chamber 11, resulting in a heavier deposit of bers at the brim portion.

Movement of the diffuser toward its Figure 4 position reverses the effect. The air block caused by the diffuser is no longer adjacent brim section 12b resulting in heavier ber deposition at tip portion 12a. A variety of diffuser positions may be utilized and, in fact, constant automatic adjustment'thereof during ber deposition is within the contemplation of my invention. In fact, by diffuser adjustment, any desirable lay and thickness of bers can quite readily be obtained, thus to form a bat having prescribed characteristics.

The position of the diffuser and the amount of pure air, i. e., non-ber-laden air owing therefrom are both factors in determining the thickness of the ber deposit. The position of the diffuser determines the location of the thickest ber deposition. The amount'of non-ber- Iladen air determines the proportion of ber deposition between the thickest and thinnest sections of the bat. Hence, the larger the ow of non-ber-laden air, the greater the ratio between the thickest and thinnest sections.

Accordingly, by way of a supplemental control, I preferably provide a damper 73 (Figure l) in riser 1S, which may be adjusted in'conjunction with dampers 25 and 26 and with diffuser 37 so as to create in air inlet 16 the exact type of ber-laden air ow as will most effectively coact with the ow of air through diffuser 37 to attain the results desired.

As pointed out hereinbefore, duct 14, yin addition to providing recirculated air to riser 15, also opens into the work room by Way of its end 14c. In this way, the

lair withdrawn from forming chamber 11, high in moisture and heat content, is recirculated in the desired amount, the remainder being exhausted through duct end 14C. Thus temperature and humidity of the air used for deposition may be easily and economically controlled. j

InFigure 5, there is shown a modication ofthe machine'shown in Figure l wherein substantially all of the air withdrawn from the forming chamber 11 may be recirculated by passage through duct 14 and back into the diffuser 37 in a manner to be described. Thus, ductk 14 is connected to a vertical duct 80 and a flexible duct 81 is connected to inlet 46 of tubular member 39 forming the centrally disposed part of ldiffuser 37. Vertical duct 80 -has an air outlet damper 82 and disposed thereabove is a valve or damper 83, the adjustment of which determines the amount of air to be recirculated in the system via ducts 80 and 81. An air inlet damper 84 is disposed in passage Sil above the damper 83.

Accordingly, in operation, dampers 73, 25, 83 and 84 may be adjusted to determine the amount of recirculated air to be directed back to the annular passage 35a adjacent the diffuser and to the inner tubular member 39 thereof by way of passages 80 and 81. Any recirculated air not wanted will exit through the air outlet `82 and air in the machine may be replenished by way of the air inlet controlled by the damper 84. Under certain circumstances, depending upon humidity and temperature conditions in the room Where the machine is operating` and on the character of the bats being formed by the machine, it may be desirable to recirculate substantially all of the air thus maintaining a closed circuit from the forming chamber and back to the form by way of the diffuser 37 and the annular passage 35a surrounding it. In this embodiment of the invention, such operation is possible and any small losses of air in the system will be automatically replenished by way of the air inlet controlled by damper 84. v

`In Figures 6 and 7, there is shown a modification of 6 the diuser wherein the cylindrical support 38 slidably carries the tubular member 39 as described above with respect to Figures 1 and 3. In this embodiment, however, there is interiorly disposed in member 39 a web structure generally indicated at SS comprising radially disposed ns 86 which support a centrally located tube 87. This tube 87 is thus secured to tubular member 39 to slide therewith and it has slidably disposed therein a rod 88 carrying on its forward end as best seen in Figlure 6 an air deflector 89 which may take a variety of shapes according lto results desired but is here shown generally pear-shaped. As indicated by the dotted lines, rod 88 may be slidably adjusted to move the detlector 89 to any desired position with respect to support 38, tubular member 39 and form 12. Thus, in this embodiment not only is the tubular member 39 adjustable to achieve the results describedabove with respect to Figures 3 and 4, but also air defiector 89 is independently adjustable to achieve further adjustment of the air currents as they are directed ltoward the form thereby to effect a ber deposition on the form precisely in accordance with the requirement of each particular job.

In the foregoing, the description has been directed primarily to the use of my machine in the batting industry. This however, should not be interpreted in a limiting fashion, for the machine has also successfully deposited other bers on a perforated form. I have found that glass bers with a resin can successfully be deposited on the inner side of the form and upon introduction of heated air, a bat or pre-form can be successfully and efficiently made for subsequent molding for nal hardening. By virtue of the provisions for recirculation of the air in .the machines here described, heat is conserved so they are less costly to operate.

It may now be seen ythat I have provided a method and apparatus for depositing brous material on a form that attains the several objects set forth hereinabove in a thoroughly practical and efficient manner.

As many possible embodiments may be made of the mechanical features of the above invention and as the art herein described might be varied in various parts, all without departing from the scope of the invention, it is to be understood that all matter hereinabove set forth, or shown in the accompanying drawings is to be interpreted as illustrative `and not in a limiting sense.

I claim:

l. In ber depositing apparatus, in combination, a forming chamber, means rotatably mounting a perforated form therein, said form having an open end disposed adjacent one end of said forming chamber, a blower for spacetherebetween, said tubular member opening into the atmosphere to direct non-ber-laden air -to said form.

2. The 'combination defined in claim l wherein there is a passageway connecting the exhaust fan with said mixing area so that a part of the air exhausted from said forming chamber may be recirculated with the berladen air to said mixing area.

3. The combination dened in claim l wherein the outlet of said fan is connected to ,the inlet of said tubular member so that air exhausted from said forming chamber may be recirculated with the ber-laden air to said mixing area.

4. In ber depositing apparatus, in combination, a forming chamber, means rotatably mounting a perforated form therein, said form having an open end disposed adjacent one end ofrsaid forming chamber, a blower for exhausting air from said forming chamber at the opposite end thereof, ber feeding mechanism including a housing leading to and facingthe open end of said form to provide a mixing area, diiusing means including a tubular member extending into said mixing area axially and spaced from said housing to provide an annular space therebetween, said tubular member opening into the atmosphere to direct non-liber-laden air` to said form, and means for adjusting the position of said tubular member with respect to said form.

t 5. In fur depositing apparatus, in combination, a forming chamber, means rotatably mounting a perforated form therein, `said form having an open end disposed adjacent one end of said forming chamber, a blower for exhausting air from said forming chamber at the opposite end thereof, ber feeding mechanism including a housing leading to and facing the open end of said form to provide a mixing area, diffusing means .including a cylindrical supporting member extending into said mixing area axially and spaced from Vsaid housing to provide an annular space therebetween, said diffusing means opening into the atmosphere to direct non-fiber-laden air to said form, and a tubular member slidably disposed in said cylindrical supporting member and being flared at the end thereof facing said form to direct air outwardly.

6. In fur depositing apparatus, in combination, a forming chamber, means rotatably mounting a perforated form therein, said form having an open end disposed adjacent one end of said forming chamber, a blower for exhausting air from said forming chamber at the opposite end thereof, fiber feeding mechanism including a housing` leading to and facing the open end of said form to provide a mixing area, diffusing means including aV cylindrical supporting member extending into said mixing area axially and spaced from said housing to provide an annular space therebetween, said dilusing means opening into the atmosphere to direct non-fiber-laden air to said form, a tubular member slidably disposedl in said cylindrical supporting member, and a deflector centrally disposed with respect to said tubular member and extend ing toward said form to deflect non-iiber-laden` air owing from said tubular member toward said form.

7. The combination defined in claim 6 in which the deector is a hollow tube smaller in diameter than said tubular member and extending from the end thereof, the extending portion being tiared to deect the air stream flowing out of said diffusing means.

8. ln apparatus of the character described in combination, a forming chamber, a form having a perforated closed end and an :open end, means for rotatably supporting said form in said chamber with the open end facing one end of said forming chamber, a blower connected to the opposite end of said forming chamber, to exhaust air therefrom, a passageway connected to the blower outlet and having a gate opening to the atmosphere, fiber feeding mechanism including a housing forming a mixing chamber adjacent to the open end of said form, diffusing mechanism extending into said mixing chamber from the atmosphere, means forming an opening in said last mentioned housing, a conduit connected to said passageway between said blower outlet and said gatf.` and also connected to said housing to lead air from said passageway to said mixing area.

9; In ber depositingapparatus, in combination, a form v having a perforated closed end and an open end, a blower 6 for drawing air through said form, liber delivering means including a casing forming armixing area adjacent the open end of said`form, `a diffuser including a tubular member centrally located with respect to said mixing area, said tubular member leading to asource of nonfiber-laden air whereby fibers delivered to said mixing area are directed by the stream of non-ber-laden nir owing through said tubular member and deposited on the inner surface of said perforated form as air is drawn therethrough by said blower, said tubular member be ing slidably mounted in said casing to move toward and away from said form, and an air detlector disposed in said tubular member.

l0. In fiber depositing apparatus, in combination, a forming chamber, a conical perforated form disposed in said forming chamber with its larger end disposed adjacent the entrance thereof, a mixing chamber disposed adjacent the entrance of said forming chamber, a blower for drawing air through said mixing chamber, said form and said forming chamber, a fiber inlet passageway leading to said mixing chamber, and` means for diffusing the fiber-laden air drawn into said mixing chamber, whereby said fiber-laden air is unevenly distributed to different portions of the interior of saidY conical form, said diffusing means including means for directing a non-liber laden stream of air into said mixing chamber substantially adjacent the entrance of said forming chamber.

11. The combination defined in claim 10 which includes ducts for directing some of the air from said blower to said' diffusing means.

12. In fiber depositing apparatus, in combination, a conical form having a perforated closed end and an open end, a blower for drawing air through said form, fiber delivering means including a casing forming a mixing region adjacent thecpcn end of said form, diffusing means including a tubular member for directing a nonber laden streamA of air drawn into said mixing region for diffusing the fiber-laden air drawn `into said form whereby saidber-laden air is directed to different ,por-` justed with respect to the adjacent ends of said tubular` member and said form.

References Cited in the file of this patent UNITED STATES PATENTS 11,756 Rankin Oct. 3, 1854 26,395 Fitzgerald Dec. 6, 1859 164,544 Gill July 15, 1875 260,918 Yule et al. July `11, 1882 672,203 Brew et al Apr. 16, 1901 2,175,454 Cassie Oct'. 10, 1939 2,277,042 Clark Mar. 24, 1942 2,474,971 Casse Iuly 5, 1949 

